Method of joining together a terminal connector and an electric cable



July 12, 1966 E. B. RAYMOND ETAL 3,259,981

METHOD OF JOINING TOGETHER A TERMINAL CONNECTOR AND AN ELECTRIC CABLEFiled Nov. 19. 1963 I 2; 5 M 1 7% 2 1 IN ENTOREI Egan E 74/440447 .4A554 /5 1, Jaw/445R United States Patent 3,259,981 METHOD OF JOININGTOGETHER A TERMINAL CONNECTOR AND AN ELECTRIC CABLE Eugene B. Raymond,Skokie, and Leslie L. Schiller, Niles,

IlL, assignors to Triple A Specialty Co., Chicago, Ill.,

a corporation of Illinois Filed Nov. 19, 1963, Ser. No. 324,673 1 Claim.(Cl. 30-289) Our invention relates to a new and improved method ofjoining together a terminal connector and an electric cable having aconductor core encased by insulation so as to provide positive contactbetween the connector and the cable to prevent withdrawal of the cablefrom the connector.

Prior to our invention it was the common practice in the art of terminalconnectors used for connecting a terminal cable electrode of asparkplug, to provide in the connector a prong which was driven into theinsulation of the cable to pierce the electrical conductor core thereof.It was also a common practice to provide a terminal connector with aprong which was driven int-o the end of the terminal cable to contactthe core thereof.

With the requirement that terminal cables used in connection withinternal combustion engines be formed of radio-resistant material, theseknown methods of joining a terminal connector to the end portion of aterminal cable have proven unsatisfactory. This resulted from the factthat in certain instances the prong driven into the cable either fromthe side or from the end thereof, would cut or otherwise damage orrupture the conductor core, thus forming a weak or defective contactbetween the terminal connector and the conductor core of the cable. Ourimproved method has for its principal object the elimination of theseand other known defects of the prior art methods of joining a terminalconnector to a conductor core.

Other objects will appear hereinafter.

The invention consists in the novel method and embodiment of parts to behereinafter described and claimed.

The invention will be best understood by reference to the accompanyingdrawings, in which:

FIG. 1 is a plan view of a notching tool;

FIG. 2 is a side elevational view of the same;

FIG. 3 is a fragmentary side view of an electrical cable;

FIG. 4 is a side view of the end portion of the electrical cable shownin FIG. 3, showing a part of the insulation thereof notched out;

FIG. 5 is a fragmentary sectional detail view showing the terminalconnector and cable connected together by our improved method;

FIG. 6 is a plan view of a blank from which our connection is formed;

FIGS. 7 and 8 diagrammatically illustrate dies for forming certain partsof our connector.

In carrying our improved method into effect, we form in the terminalcable 10 a notch 11. This notch 11 extends transversely and inwardlyfrom the end portion 12 of the cable 10 and is of a depth to expose at13 a surface portion of the electrical conductor 14. This electricalconductor in the present instance comprises a plurality ofnon-conductive thread-like strands 15 which may be formed of anysuitable material, such, for example, fiber glass. These strands areencased in a conductive coating 16 of any suitable material, such, forexample, carbon. The conductor core 14 is then encased in an insulatingmaterial 17 which is notched to provide the notch 11 hereinbeforereferred to.

The notch 11 may be formed by any suitable notching tool, such, forexample, as shown in FIGS. 1 and 2. In this connection, the toolcomprises a pair of handle members 18 and 19 connected together inscissors fashion by a bolt or pivot 20. The handle member 19 ischannelshaped in cross section and at one end thereof is provided anelongated slot 19' through which the end portion 18 of the handle member18 projects.

The handle member 19 has a transverse elongated tubular holder 21provided with a circumferential slot 22 on one side of its long axis.The handle member 18 provides a cutting tip 23 which passes through theslot 22 when the handle members 18 and 19 are pivoted toward each otherby grasping the portions 29 thereof.

The end of the cable to be notched is positioned in the tubular holder21. The handle members 18 and 19 are pivoted to bring the cutting tip 23into cutting relationship with the cable 10. This operation provides thenotch 11 which extends transversely of the cable 10 a suitable distancefrom the adiacent end of the cable and is of a depth sufficient toexpose the surface portion 13 of the core 14.

After the notching operation a conductive connector C is attached to thenotched end nortion of the cable. From one end portion of a blank 24' anopen ferrule 24 is formed. Struck therefrom. from the bottom wall thereof, is an elongated relatively flat transversely extending contactplate 25. The forming of the ferrule 24 and the striking therefrom ofthe contact plate 25 is accomplished by dies D diagrammaticallyillustrated in FIG. 7.

The notched end portion of the cable is placed in the open ferrule withthe contact plate projecting into the notch in positive contact with theexposed portion of the core 14. After the nitched end portion of thecable is thus placed in the open ferrule, the side walls 26' thereof arefolded inwardly upon the cable forming, together with the ferrule, asleeve clampingly embracing the notched end portion of the cable therebyto fixedly secure the contact plate in the notch in pressing contactwith the exposed surface of the core. The folding of the side walls ofthe ferrule upon the cable may be accomplished by any suitable formingdies such as are illustrated in FIG. 8, at E.

The connector C is more fully disclosed in our copending applicationfiled on even date hereof, and bearing Serial No. 324,711.

When the terminal connector C is connected to the cable 10 by ourimproved method, the contact plate 25 cooperates with the notched-outportion 11 of the cable to prevent withdrawal of the notched end portionof the cable from the ferrule 24.

In disconnecting the sleeve 27 from the electrode of a sparkplug 28, oneinvariably grasps the cable 10 and pulls in a direction to accomplishsuch disconnection. This pulling on the cable in the methods of theprior art hereinbefore described, generally results in a breaking of thecontact between the connector and the core of the cable, or thedisconnection of the cable from the terminal connector. By our improvedmethod this cannot take place because of the cooperation of the contactplate 25 and the notch 11 in the cable 10.

The various advantages and objects of the invention may be accomplishedby modifications of the particular method and embodiment specificallydescribed herein, and it is intended that the appended claim shallinclude all equivalent arrangements and methods coming within theircall.

Having thus described our invention, what we claim as new and desire toprotect by Letters Patent is:

A tool for notching a portion from the side of an insulated terminalcable to expose the electrical conductor core thereof, comprising (a) apair of handle members pivotally connected together inwardly ofcorresponding end portions thereof,

(b) a holder for said cable comprising a sleeve formed integrally withan end portion of one of said members and extending transversely of thelong axis of said one member,

(0) said sleeve having a slot formed in one side thereof in acircumferential direction with respect to said sleeve,

(d) and a cutting tip formed on an end portion of the other of saidmembers and movable into said slot through an are passing through theinsulation of said cable on one side of the long axis of the cable fornotching out a side portion of said cable to expose the conductor coretherein.

References Cited by the Examiner UNITED STATES PATENTS EDWARD C. ALLEN,Primary Examiner.

JAMES L. JONES, ]R., Examiner.

